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Burnham PVG Boiler User Manual

Contents

1. 8 G3riddns SHAU 32 33 peBexoeg uaelsAS uoz 4 aH mow NMOHS pos 1 14 EN MSN Ilir moa TT WNIGINI r J la Ife Li H p Il Il p I wowwowo i T ralss J 4 220s SSS a L J His 11 ONY ami os v 9 re J 1 IVLSOPRGHL MGTMYISN danddns SINN SIUM 3 5 4 TW X380 XB NWI YOM 35 ir ONY 375 Noud0 Jo3NNOosM 1531 1 3002 TORLO G TWNOUWN OL 13 38 r1 NOUDMONA SNOU23NNOO uod NO LYOHSUNY 3SN L t L g a I arrvisN oo 1462 80102 pue 1 s 55
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3. M3TWISNI AB aanddns SAU z S lt S c z 7 o 5 E gt S 5 lt lt z o 2 5 Eod 4 o 5 D o gt 7 c c walsAS p uoz 8 9119 9 MOTGA 2 NMOHS 998 f SS3NMVH M3WHO3SNVMI 58295 1VISONWM3HL 19150 3802 3NOZ 2 3NOZ 3NOZ MO a3sn 4 M3TIVISNI AB Q3riddns SHAU OL 135 33N3un8 Nouvoriddv SIHL 303 TVnNVM 88883 OL 3438 SI 88884 TWNOLUGGY Q3sin034 S3NOZ SHON 31 am l 5 e M3TIVISNI AB ddnddns SLAN TW 1 SIYIN 39YLIOA G3SOdX3 TIV 318 2 ISN 3dAL 3215 S3NOZ 304 888884 35 1531 1 3002 WOLONI TVNOUVN OL 43434 S3NOZ 303 8888 35 NO NOLLSOd NO BNvd 3NOZ 99993 SNOLLO3NNOO 9 3 3 OL HOUMS 13S aanddns N3TYVISNI 8 TV NO LNOHSUNY ISN NOIVInOMIO NOIVInOMIO L INOZ NO EYNI Q3TIVLSNI AMOLOY4 3NOZ 3NOZ Z3N0Z 0351 dl
4. o Buidid JU 9A uoneuliul9 9 NOLVOllddv Avg 1510 V OL MVIIAIS N3dO 3015 3NO 15 31 LV Q3TIVISNI SI 1N3A N3HM S3HONI 33389H1 MO 3SVHO Q3SO19N3 ATINA V NI G3TIVISNI SI INJA N3HM S3HONI v YNOS SI WIYSLVW 311815 8 OL 3ONV3HV3IO AnAINIA ddid LN3A gt lt TVNIWMSL INA 1VOLLNHA m Svo 3 14 ONIHSV 14 SOLIS 1MOddnS GNV8 4 034 341 JOVYd TWNINYSL IN3A TT 18 F Optional Exterior Separate Horizontal Vent Terminal Mounting See Figure 9 1 Do not exceed maximum vent lengths Refer to b After penetrating wall thimble install an Table 4 AL 29 4C 90 elbow so that elbow leg is in the 2 This installation will allow a maximum of seven up direction 7 feet vertical exterior run of the vent piping to be c Install maximum of five 5 feet of AL 29 4C installed vent pipe Refer to Sections C through E for proper procedures for joining vent pipe and NOTICE fittings Exteri to be included i ivalent t d Install AL 29 4C 45 elbow to upper AL 29 4C 90 elbow so that leg of 45 is in down direction lengths see Figure 9 3 Install vent piping f Install vent terminal g Brace piping if required a Install vent piping for desired venting system Refer to specific section for details for vent pipe installat
5. 31 AUNOA en o iso esf en n isa en o i isole 3 d 2020 SE Pea ind n 3 7130 3ATVA 3NOZ INI 1431035815 335 Q3riddns SHAU 35 VALVE CONNECTION 36 HONEYWELL VC VALVE pia SERIES 20 80 ES1 V1 V2 V3 N C HONEYWELL Eu V8043E ES1 V1 v2 V3 HONEYWELL n V8043F ES1 V1 v2 V3 TACO 571 2 ES1 3 V2 1 R8889 ZONE ZONE VALVE WHITE ROGERS 2 1311 102 ES1 V1 V2 V3 WHITE ROGERS ais 13A02 102 ES1 V1 V2 V3 ERIE FS2 0767C0008GAO0 ES1 v1 2 V3 ES2 ES1 V1 V2 V3 R8889 ZONE VALVE CONNECTION ZONE VALVE JUMPER TO 51 WHEN USING VALVES WITHOUT END SWITCHES Figure 20 Different Manufacturer s Zone Valve Connections to Honeywell R8889 VII Modular Installation A General Guidelines 1 Read and follow all venting combustion air water piping gas piping and electrical instructions contained in this manual unless otherwise instructed in this section 2 Consult Local Building Codes or National Fuel Gas Code NFPA 54 ANSI Z222 3 for restrictions and instructions on modular boiler installations B Module Sizing Burnham recommends sizing each boiler in a modular system to provide 20 of the combined heating load where ever possible C Venting Each boiler must have an individual vent pipe Refer to Venting
6. 30939 46 SdValS LYOddNS 13 TU 13 uonej ejsu JUBA IeluozloH ejeudeg v 91 6 1 331 31VSN3QNOO V N3HM NIN 1003 33d v 33108 JHL 34015 LSNW SNNY IWLNOZINOH TION NOLYONddY AVG 1510 V OL YVIINIS 340 3015 15 31 43 51 INJA S3HONI 333HL YO NOILYONddY 3SVHO ATINS V NI G3TIVISNI SI 3 N3HM S3HONI 3n03 51 TYIJ3lYA JIJILSNANWOO OL 3ONVMY310 WNWININ LINIA ASIA LATI ANA TNAM 3181sn8AO09 NON 304 TYNOLLdO lt 318 TYM 319NIS VM a18usngWno A JIGNIHL TYM 318noq lt lt gt 30074 OL 310N 33S 3dld INJA MONS XVA SdV4LS NIN 2 1 1 331 Nivad 31VSN3qN0O 14 p 10 uoneunByuo jeuruue jejuozuoH 6 ainbi4 LNHWA TVLNOZINOH TV TYM 3O1331X3 66 421 3381lsn8Woo 31 Q3MInO33 318NIHL TVM 9nONHl 310H 8 431108 M WNINYSL 3 YOOGNI M Q3Qn19NI 0813 St QNV8 9NI3201 MO 14 99 3M4 j winvo 3NOOhIS JOOMdM3HI1V3M TIVNIWGISL INJA TVLINOZIYOH TYM 3OIN31X3 XV 66 11 TIVM 318 15
7. Low Water Cut Off LWCO on Hot Water Boilers Optional WARNING DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off LWCO Only use connections specifically identified for Low Water Cut Off In all cases follow the Low Water Cut Off LWCO manufacturer s instructions When A low water cutoff is required to protect a hot water boiler when any connected heat distributor radiation Is installed below the top of the hot water boiler i e baseboard on the same floor level as the boiler In addition some jurisdictions require the use of a LWCO with a hot water boiler Where The universal location for a LWCO on both gas and oil hot water boilers is above the boiler in either the supply or return piping The minimum safe water level of a water boiler is at the uppermost top of the boiler that is it must be full of water to operate safely What Kind The PVG boiler is designed to accept the wiring of the Safgard Model 1100 H4 LWCO P N 100592 01 This 15 a probe type LWCO The factory wiring is designed to allow simple Plug in installation of the wiring How to Pipe A tee is commonly used to connect the probe LWCO to the supply or return piping as shown below SYSTEM SYSTEM SUPPLY RETURN MINIMUM SAFE WATER LINE LWCO Location Select the appropriate size tee using the LWCO manufacturer s instructions Often the branch connection must have a minimu
8. Inc specifically disclaims liability of any kind caused by or relating to improper installation 4 Proper Use and Maintenance The warranties extended by U S Boiler Co Inc conditioned upon the use of the residential grade water boiler for its intended purposes and its maintenance accordance with U S Boiler Co Inc recommendations and hydronics industry standards These warranties will be inapplicable if the residential grade water boiler is used or operated over its rated capacity is subjected to unauthorized modification or is damaged as a result of being otherwise improperly operated or serviced including but not limited to damage from any of the following operation with insufficient water allowing the boiler to freeze subjecting the boiler to flood conditions and operation with unapproved water or fuel additives which cause deposits or corrosion 5 Removal and Installation These warranties do not cover expenses of removal or reinstallation The owner is responsible for the cost of removing and reinstalling any defective part and its replacements and all labor and material connected therewith 6 Exclusive Remedy U S Boiler Co Inc obligation for any breach of these warranties is limited to the repair or replacement of its parts in accordance with the terms and conditions of these warranties 7 Limitation of Damages Under no circumstances shall U S Boiler Co Inc be liable for incidental indirect special or con
9. REMOVE MV LEAD AT MODULE IF VALVE CLOSES RECHECK TEMPERATURE CONTROLLER AND WIRING iF NOT REPLACE GAS CONTROL YES REPEAT PROCEDURE UNTIL TROUBLE FREE OPERATION 15 OBTAINED Figure 24 Troubleshooting Guide 43 THERMOSTAT CALLS FOR HEAT RELAYS ENERGIZED CIRCULATOR STARTS BLOWER STARTS PRESSURE SWITCH NORMALLY CLOSED POSITION TO NORMALLY OPEN POSITION IGNITION MODULE ENERGIZED 30 45 SECOND DELAY PREPURGE IGNITION SOURCE ENERGIZED PILOT GAS ON TRIAL FOR IGNITION PILOT NO PILOT CONTINUOUS LIGHTOFF LIGHTOFF RETRY IGNITION IGNITION SOURCE OFF SOURCE OFF MAIN GAS ON PILOT GAS OFF CALL FOR DELAY 5 HEAT ENDS MINUTES RELAY BLOWER DE ENERGIZES STOPS IGNITION CIRCULATOR MODULE OFF STOPS GAS VALVE CLOSES Figure 25 Sequence of Operation I Sequence of Operation See Figure 25 If boiler fails to operate properly see Troubleshooting Tree in Section IX Service J Check pilot burner flame See Figure 27 Flame should be steady medium hard blue enveloping 3 8 to 5 inch of sensing probe K Check main burner flame See Figures 26 Flame should have clearly defined inner cone with no yellow tipping Orange yellow streaks should not be confused with true yellow tipping 44 y pping INCANDESCENT OUTER MANTLE BLUE WITH OCCASIONAL DRANGE FLASHING OUTER CONE DARKER TRANSPARENT BLUE INNER
10. Recommended horizontal installation consists of vent being sloped down inch per foot away from boiler See Figures 4 and 4A Use appropriate designed thimbles when passing through combustible walls thimble use optional for noncombustible walls Insert thimble through wall from outside Secure outside flange to wall with nails or screws and seal ID OD and vent holes with sealant material Install inside flange to inside wall secure with nails or screws and seal with sealant material For noncombustible wall application when thimble Is not used size opening such that bell with locking band attached cannot pass through Join vent terminal to vent pipe See Figure 5 Insert vent pipe through thimble opening from outside and join to vent system Apply sealant between vent pipe and opening thimble to provide weathertight seal uonej ejsu JUBA IeJuoziuioH NOLIVOllddv AVE LSIOF V OL MVIIWIS N3dO 3015 JNO 1SV31 LV Q3TIVISNI SI INJA N3HM S3HONI 33MHL YO 3SvHO q3S019N3 ATINS V NI Q3TWVISNI SI INJA N3HM S3HONI v YNOS MAIA ACIS LINT 51 WIYSLVN 3181518 400 OL 3ONV8V31O WAWININ 3dld LINJA TYM 3181S08A09 NON 3034 IVNOlLdO 318WIHL TIVM 319NIS NYM 318 5 404 93510354 318 318n0G 1003 Yad 33108 WOMJ AVMV 34015 5 SNNY 1VINOZIMOH 3dld INJA NOILVINNNDOV MONS
11. boiler wires black white and Code green located in the junction box at the inside top of the boiler jacket If a low water cutoff is to be used connect the low water cutoff so that all 120V power to boiler is interrupted if the low water cutoff s switch opens B Aseparate electrical circuit must be run from the main electrical service with an over current device disconnect in the circuit A service switch is recommended and may be required by some local jurisdictions Install the service switch in the line C Refer to Figures 14 and 15 for details on the internal voltage Hot leg of the power supply Locate the boiler wiring NOTICE This boiler is equipped with a high water temperature limit located inside the internal wiring of the boiler This limit provides boiler shutdown in the event the boiler water temperature exceeds the set point of the limit control Certain Local Codes require an additional water temperature limit In addition certain types of systems may operate at temperatures below the minimum set point of the limit contained in the boiler If this occurs install an additional water temperature limit Honeywell L4006 Aquastat located in the system piping as shown in the Water Piping and Trim Section of this manual Wire as indicated in the Electrical Section of this manual NOTICE All wire wire nuts controls etc are installer supplied unless otherwise noted 28 weibeig Jellog
12. ji 938033 PER rA eo O gt 431108 M TWNINNSL 3 ll YOOGNI M MO813 SNI22901 x 10v29 3NOOI1IS M jOOMdM3H1V3M 15 E Vertical Venting System See Figures 6 7 and 8 16 NOTICE Roof penetrations require the use of roof flashing and storm collar not supplied with boiler Vent Piping 1 Do not exceed maximum vent lengths Refer to Table 4 Installation of a vertical vent tee 81163040 is required on all vertical vent applications See Figures 6 and 7 Attach vertical vent drain tee directly to elbow or horizontal pipe from an elbow immediately after vent connector Slope horizontal runs minimum inch per foot Slope towards vertical vent drain tee Position weld seams in vent pipes in all horizontal runs at the top to avoid condensate from lying on the seams Install fire stops where vent passes through floors ceilings or framed walls The fire stop must close the opening between the vent pipe and the structure Whenever possible install vent straight through the roof Refer to Figure 7 if offset is necessary Maintain minimum clearance to combustible materials a Install Vent Terminal Size roof opening to maintain minimum clearance from combustible materials Extend vent pipe to maintain minimum vertical and horizontal distance of twelve 12 inche
13. 4 340 102 S3ATVA 7 NOLLV1OSI 7 1804 TNA h 11 8 d 4 n 3ATVA SSVdA8 G3SN SI 40025 MIV TWNOLLNSANOO 31 E Uie 81 S3AWA 3 33lV3H 3ONVITIV 3NOZ 094 S3NOZ TWNOILIGGY 23 suui s s p uoz eauoz 1972M Z oJnDiJ MAIA LAAT 331108 40 1NOMJ 30073 30 9 Q NIHLIM 3 331133 3ynss3yd AlddNS 31 4 I es 1134 N3LSAS YNVL NOISNVdX3 TYNOILdO ddns 340 1002 M3lVM 0709 M3lVM 3 NOILV1OSI 939939 41 3ATVA SNIOnQ33 4 JAYA M93HO 3JO 1nHS 3M SS3Md W3LSAS 1304 1113 S3NOZ 3 Ya l WNOILIGOV IOI 91 1 Yono t JAVA N31SAS SSvdA8 3 3NOZ dOOOS 0351 SI 40025 3 31 3 1N3A NIN SL 39ynd 3ATYA ONIONVIVE S3ATVA 2 V m D aasn 31 3ONVITIV OL OL 3ONvITIV OL 3 S3NOZ VNOILIGQV NOYS ve r h 24 V Gas Piping Table 7 for maximum capacity of Schedule 40 pipe WARNING Table 8 lists equivalent pipe length for standard Failure to properly pipe gas supply to boiler may fittings result in improper operation and damage to t
14. 9 HOLD CABLE NEAR TERMINAL IS SPARK PRESENT DID BLOWER OPERATE FOR 30 TO 50 SECONDS BEFORE SPARK BEGAN YES TURN ON GAS SUPPLY DOES PILOT BURNER LIGHT DOES SPARK STOP AFTER PILOT IS LIT YES MAIN BURNER LIGHTS YES BOILER CONTROL SYSTEM SEQUENCING PROPERLY CHECK DISTRIBUTION SYSTEM TURN OFF GAS SUPPLY ADJUST THERMOSTAT TO CALL FOR HEAT DOES BLOWER ENERGIZE 24 VOLTS AT CONNECT MANOMETER TO CONNECT CONNECTED TO PRESSURE SWITCH PRESSURE SWITCH SEE GANOPY TUBING TO TERMINAL NO FIGURE 31 IS DIFFERENTIAL CANOPY CHECK IGNITOR SENSOR CABLE GROUND WIRE CERAMIC INSULATOR AND GAP CHECK IGNITOR SENSOR CABLE BOOT FOR GO TO NEXT PAGE TUBING SECURELY PRESSURE GREATER THAN MINIMUMS LISTED IN TABLE 15 YES CRACKS OR HOLES REPLACE TUBING CLEAR OBSTRUCTIONS YES REPLACE PRESSURE SWITCH NO REPLACE IGNITION MODULE VENT AIR INTAKE NO SYSTEM FREE OF OBSTRUCTIONS YES REPLACE BLOWER YES SIGNS OF MELTING OR BUCKLING NO REPLACE IGNITION MODULE NO NO ALL MANUAL GAS VALVES OPEN OPEN VALVES YES NO 24 VOLTS ACROSS IGNITION MODULE TERMINALS AND 24 VOLTS ACROSS GAS VALVE TERMINALS PV NO REPLACE IGNITION MODULE MV PV YES REPAIR OR REPLACE WIRES IS GAS SUPPLY PRESSURE BETWEEN 4 5 amp 13 5 IWC FOR NATURAL amp 11 0 amp 13 5 IWC FOR LP AND MV PV
15. 9 580 6 318 2 lnodlo 3 Y3MOd 2 81 3215 0 9 501 O3ONVMIS WMW MAL 3dAL 3MIM 8L 3ZIS 39 GNWDWI WVSUDVId 908077 TI3MA3NOH Ex X34009 aviss w3AMOJSNVML 7IVUN33334I0 3unss33d n aus AV133 Arz su3Hi0 A8 1915 vZ aL ios o amp Anddns M3TWISNI A8 G3NddNS 38 SWALI 353 1 29 NOTICE Ifan additional system limit is used install in series with the auxiliary limit jumper shown in the drawing below L1 N GND POWER SUPPLY 20 60 BY INSTALLER BLOWER BR 1 OVERCURRENT PROTECTION DISCONNECT CIRCULATOR INSTALLER MOTOR SERVICE SWITCH OPTIONAL BY INSTALLFP J B0X 24V TRANSFORMER GND SCREW 2 ESTA BY OTHERS 6 CR 2 D 2 FRS 2 ty es d LWCO AUX LIMIT JUMPER JUMPER m BR 2 NO DIFFERENTIAL cradles RELAY PRESSURE SWITCH WIRE CODE BK BLACK BL BLUE BL WH BLUE W WHITE TRACER GR GREEN IGNITI OR ORANGE MODULE 0 PI PINK RD RED WH WHITE YE YELLO T GND GROUND 2 A GAS V
16. APPLICATION OR THREE 3 INCHES WHEN VENT IS INSTALLED WITH AT LEAST ONE SIDE OPEN SIMILAR TO A JOIST BAY APPLICATION 2 AREA OF EACH OPENING 1 SQ INCH FOR EACH 1000 BTUH INPUT WITH MINIMUM OF 100 SQ INCHES HEIGHT OF OPENING SHOULD BE HALF THE WIDTH 3 USE DOUBLE WALL THIMBLE WHEN PENETRATING A COMBUSTIBLE WALL 4 18 INCH CLEARANCE REQUIRED FOR CLOSET INSTALLATION 4 INCH CLEARANCE REQUIRED FOR OPEN INSTALLATION Figure 1 Minimum Clearances to Combustibles DIMENSIONAL DATA TVNOISN3NWIQ Suolsueuld z 13 1 043 5531 3 0291 JAWA 5 9 ONIdid 38 7041409 9 AV 7041409 Am3y 43N303SNVHL 39nv9 3unss3ud 3snivs3dW3L 3 3 9NIdld AlddNS SN3H10 A8 ONIdid 3AWA i3nas 3AWA 3334 SY3HLO A8 SY3H10 A8 ONIdid 9Nldld 3 AlddNS Sv9 HOLIMS 38 55384 SHHONI NI SNOISNSWIGd SAZIS NOLLOSNNOO I Pre Installation WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage or personal injury DANGER Do not install boiler where gasoline or other flammable vapors or liquids or sources of hydrocarbons i e bleaches cleaners chemicals sprays paint removers fabric softeners etc are used or stored NOTICE Due to the low water content of the boiler mis sizing of the boiler with regard to the heating system
17. Adjust gas input rate to boiler 1 Adjust thermostat to highest setting 2 Check manifold gas pressure See Table 5 or rating label located in the boiler s vestibule compartment Adjust gas valve pressure regulator as necessary turn adjustment screw counterclockwise to decrease manifold pressure or clockwise to increase manifold pressure If pressure cannot be attained check gas valve inlet pressure If less than minimum indicated in Table 5 or boiler s rating label contact gas supplier for assistance 3 Clock gas meter for at least 30 seconds Use Table 13 to determine gas flow rate in Cubic Feet per Hour WARNING Failure to properly adjust gas input rate will result in over firing or under firing of the appliance Improper and unsafe boiler operation may result 4 Determine Input Rate Multiply gas flow rate by gas heating value 5 Compare measured input rate to input rate stated on rating plate a Boiler must not be over fired Reduce input rate by decreasing manifold pressure Do not reduce more than 0 3 inch w c If boiler is still overfired contact your Burnham distributor or Regional Office for replacement Gas Orifice b Increase input rate if less than 9896 of rating plate input Increase manifold gas pressure no more than 0 3 inch w c If measured input rate is still less than 98 of rated input i Remove Main Burners per procedure in Section IX Service ii Remove gas orifices Drill one 1 dril
18. CONE SHARPLY DUTLINED WITH BRIGHT LIGHT BLUE FLAME RETENTION INNER CONE PARTIALLY LIFTED FROM BURNER Figure 26 1 Inch Main Burner flame CENTER COMBINATION ELECTRODE SENSING 1 38 GROUND LEAD WHEN REQ D GROUND STRAP PILOT TUBING TRG IGNITER SENSOR LEAD BLUE Figure 27 Pilot Burner Flame L Check thermostat operation Raise and lower temperature setting to start and stop boiler operation M Check ignition control module shut off Disconnect pilot lead wires from gas valve If burners do not shutdown determine cause of malfunction Replace necessary items and check operation N Check low water cutoff if so equipped 1 Adjust thermostat to highest setting 2 With boiler operating open drain valve and slowly drain boiler 3 Main burners and pilot burner will extinguish and blower will stop when water level drops below low water cutoff probe Verify limit thermostat or other controls have not shut off boiler 4 Adjust thermostat to lowest setting Refill boiler O Check limit 1 Adjust thermostat to highest setting 2 Observe temperature gauge When temperature is indicated adjust limit to setting below observed temperature Main burners and pilot burner should extinguish and blower should stop 3 Adjust limit to setting above observed temperature Ignition sequence should begin 4 Adjust thermostat to lowest setting Adjust limit to desired setting P
19. Flue Gas Baffles Inspect Flue Gas Baffles for deterioration Inspect flue passages Clean with flue brush See Figure 30 Inspect heating surface in combustion chamber Clean with straight handle wire brush Install Flue Gas Baffles Replace Canopy Assembly and seal Connect Silicone Tubing between Pressure Fittings on Canopy Assembly and Pressure Switch Route through bushings in Vestibule Panel See Figure 28 Install Jacket Top Rear Panel Connect vent system See Figure 29 Connect Blower Motor Wiring Harness TOP VIEW Figure 28 Silicone Tubing Assembly ACK SILICONE TUBING Figure 29 Blower Vent Connector Assembly E Main Burners and Firebox Vacuum firebox Exercise care do not damage base insulation 2 Clean main burners Brush top of burners with soft bristle brush See Figure 30 Vacuum to remove any dirt and lint 3 Vacuum tip of pilot burner 4 Check gas orifices for lint and dirt Clean as necessary 5 Install main burners by reversing procedure to remove burners a Pilot burner must be installed in original location See Table 14 b Main burners must be properly secured in burner tray slot at rear of firebox and over gas orifice See Figure 30 c Pilot gas supply and pilot lead wires must be reconnected d Burner access panel must be securely in place e Reconnect Flame Roll out wires F Check operation Follow steps G through P from Section VIII System Star
20. RELAY AFTER CHECKING FOR BROKEN WIRES AND LOOSE CONNECTIONS YES 24 VOLTS AT DIFFERENTIAU NO 24 VOLTS ACROSS BOTH NO REPLACE LIMIT AFTER CHECKING FOR BROKEN PRESSURE SWITCH LIMIT TERMINALS WIRES AND LOOSE CONNECTIONS YES TERMINAL NC YES CHECK FOR BROKEN WIRES AND LOOSE CONNECTIONS 24 VOLTS ATDIFFERENTIAU wo REPLACE DIFFERENTIAL PRESSURE ir PRESSURE SWITCH TERMINAL C YES CHECK BLOWER RELAY 24 VOLTS AT COIL NO REPLACE RELAY AFTER CHECKING FOR 120 VOLTS AT TERMINALS BROKEN WIRES AND LOOSE CONNECTIONS 1 AND 32 YES REPLACE BLOWER AFTER CHECKING FOR BROKEN WIRES AND LOOSE CONNECTIONS 51 XI Repair Parts PVG Repair Parts may be obtained through your local Burnham Wholesale distributor Should you require assistance in locating a Burnham distributor in your area or have questions regarding the availability of Burnham products or repair parts please contact Burnham Customer Service at 717 481 8400 or Fax 717 481 8408 _ NUS AL 4 v Ti Ta 1549 MN Y 2 NEN I N S N N 52 1 Key Quantity Part Number N Description PVG 3 PVG 4 PVG 5 PVG 6 PVG 7 PVG 8 PVG 9 1 CASTING ASSEMBLY EAR Section Assembly 61707031 61707041 61707051 61707061 61707071 61707081 61707091 1 Left End Section End Section 71707001 1 2 3 4 5 6 7 EL 71707003 71707003 71707003 71707003 71707003 7
21. Section of this manual for venting guidelines and options WARNING Do not manifold vent pipes together 2 The maximum vent length for each boiler is fifty 50 equivalent feet 3 The minimum horizontal distance between vent terminations is one 1 foot Additional horizontal distance is desirable to avoid frost damage to the building Vent terminations must be at least twelve 12 inches above the ground plus the expected snow accumulation CAUTION Installing multiple vent terminations close together promotes frost buildup on buildings To minimize this possibility extend the distance from the building to the end of the vent termination and increase the horizontal distance between terminations 4 Multiple vertical vent pipes may be piped through a common condult or chase so that one roof penetration may be made Each vent termination must be one 1 foot from other terminations D Water Piping See Table 9 and Figure 21 Installing a low water cutoff in the system piping of modular systems is strongly recommended and may be required by Local Codes E Gas Piping 1 Refer to National Fuel Gas Code Local Codes and Tables 7 and 8 for gas pipe sizing Table 9 Modular Boiler Water Manifold Sizing Recommended Minimum Common Water Manifold Size NPT Combined Output MBH 2 Each boiler must be piped as shown in Figure 13 WARNING If gas pressure in the building is above psig an additional
22. and will be free of defects in material and workmanship under normal usage for a period of one year from the date of original installation If any part of a water boiler is found to be defective in material or workmanship during this one year period U S Boiler Co Inc will at its option repair or replace the defective part LIFETIME LIMITED WARRANTY ON HEAT EXCHANGER U S Boiler Co Inc warrants to the original owner that the heat exchanger of its residential grade water boilers will remain free from defects in material and workmanship under normal usage for the lifetime of the original owner at the original place of installation If a claim is made under this warranty during the first ten years from the date of original installation U S Boiler Co Inc will at its option repair or replace the heat exchanger If a claim is made under this warranty after the expiration of ten years from the date of original installation U S Boiler Co Inc will at its option and upon payment of the pro rated service charge set forth below repair or replace the heat exchanger The service charge applicable to a heat exchanger warranty claim is based upon the number of years the heat exchanger has been in service and will be determined as a percentage of the retail price of the heat exchanger model involved at the time the warranty claim is made as follows Years 1 10 13 15 16 In Service Service Charge as of 15 25 30 Retail Pr
23. burner flame sense wiring contamination of flame rod burner ground connection Check for pilot flame Replace gas valve if pilot flame present If no pilot flame cycle Call for Heat If error repeats replace control Reset by cycling Call for Heat If error repeats replace the control X Y flash codes signify that the LED flashes X times at 2Hz remains off for two seconds flashes Y times at 2 Hz remains off for three seconds and then repeats the sequence 42 Honeywell Electronic Ignition Troubleshooting Guide START BEFORE TROUBLESHOOTING FAMILIARIZE YOURSELF WITH THE NOTE CALL FOR HEAT 24 VAC SUPPLY IS CONNECTED TO THE 24 V TERMINAL ON THE CONTROL STARTUP AND CHECKOUT PROCEDURES CHECK LINE VOLTAGE POWER LOW VOLTAGE TRANSFORMER LIMIT CONTROLLER THERMOSTAT CONTROLLER AND WIRING ALSO CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM IF USED AND THAT THE END SWITCH IF USED IS MADE PULL IGNITION LEAD AND CHECK SPARK AT MODULE NO REPLACE MODULE SPARK ACROSS IGNITER YES SENSOR GAP CHECK IGNITION CABLE GROUND WIRING CERAMIC INSULATOR AND GAP AND CORRECT CHECK BOOT OF THE IGNITION CABLE FOR SIGNS OF MELTING OR BUCKLING TAKE PROTECTIVE ACTION SHIELD CABLE AND BOOT FROM EXCESSIVE TEMPERATURES TURN GAS SUPPLY ON AND RECYCLE CALL FOR HEAT CHECK THAT ALL MANUAL GAS VALVES ARE OPEN SUPPLY TUBING AND PRESSURES ARE GOOD AND
24. gas pressure regulator is required Using one additional regulator for multiple boilers may result in unsafe boiler operation The additional regulator must be able to properly regulate gas pressure at the input of the smallest boiler If the regulator cannot do this two or more additional regulators are required Consult regulator manufacturer andlor local gas supplier for instructions and equipment ratings F Electrical 1 Each boiler must be provided with a fused disconnect and service switch 2 Install wiring in accordance with requirements of authority having jurisdiction In the absence of such requirements follow the National Electric Code NFPA 70 and or CSA C22 1 Electric Code G Modular Boiler Control Systems Contact a controls manufacturer such as Honeywell or Tekmar to properly apply a modular control system Common systems may use outdoor temperature return water temperature or both to stage the boilers 37 W31SAS WOJ NSOL3S H ef uxog 9 d 99S Nldld W31SAS Buidid JelnpoN Lz eJnBiJ IOl z uoa 9 925 3zrivno3 SNIONVIV8 TIVLSNI SH1SN31 3dld ANY iddns 3ziivnO3 OL 9NIdld WNWININ NIVINIVA L 31ON i o8 9 d 99S Jolmnoylo IOV NO 32 6 Sdn 5044 9 TOn Z AN 9 8 L00 09Y1 M 3 NOISNVdX3 440 LAHS S 131545 SV d acr
25. three 3 zone systems and Model R8889B for four 4 zone systems Models R8889C and R8889D have less load capacity and may not operate with certain types of zone valves Up to four 4 R8889 s may be used together to provide up to sixteen 16 individual zones Only one 1 zone the first zone of the main control will provide priority zoning for the Alliance indirect water heater If more than four 4 zones are required connect additional R8889 s by wiring the A B and C terminals of each control together Each R8889 requires a 120 volt power supply If more than one 1 R8889 is used set the panel type switch to main on the first R8889 and set the panel type switch to expansion on the second third or fourth R8889 31 BuuiM AIuo euoz lBuis 9 1NOXIONJ 3 AB 43 5 SANN TW SIYM 3UHM INN TAVI 35 3dAL 325 4 o3NNoosio 1 09 021 13 3000 WORHO313 OL 3433 HdOD 90100 ma DaS Adans SNOLL23NNOO MBWOd 8 NO LYOHSUNY ISN b x L 9n N Q3TIVISNI ANOLOV4 L HM O3TMISN
26. 1 Nipple 94 NPT x Close N A 806600022 Union 72 NPT 806604023 N A N A 806604001 82207031 82207041 82207051 82207061 82207071 82207081 82207091 4 6 8 10 12 14 16 822710 822710 822710 822710 822710 822710 822710 4 6 8 10 12 14 16 822792 822792 822792 822792 822792 822792 822792 8236163 O Union 34 NPT 7 Gas Manifold 3 2 Gas Manifold Burner Orifices Natural Gas 47 Burner Orifices LP Gas 1 20 mm Pilot Assembly Natural Gas Pilot Assembly LP Gas 8236164 5G Pilot Burner 100147 01 Main Burner 3 5 7 9 11 13 15 100146 01 100146 01 100146 01 100146 01 100146 01 100146 01 100146 01 ilot Tubing 8236122 5J U 5K CD elf Tapping Screw 1 4 20 x 7 6 80860700 59 JACKET LEFT SIDE PANEL Ke Quantity Part Number N y Description 9 PVG 3 PVG 4 PVG 5 PVG 6 PVG 7 PVG 8 PVG 9 6 CONTROL PANEL ASSEMBLY Limit Honeywell L4080D 100189 01 Transformer Relay Honeywell R8285D Ignition Module Honeywell S8670E3003 100959 01 80160155U Diierential Pressure Switch 80160762 80160761 80160760 80160759 80160760 Sea Level 0 4999 High Altitude 5000 10 000 80160759 80160763 80160764 80160765 80160764 Blower Relay Honeywell R8222U1006 80160096U 60 Quantity Part Number Description 7 JACKET PARTS 7A 6040
27. 1707003 71707003 Right End Section Right End Section Section 71707002 4 6 8 10 12 14 16 uuu sia 806600009 806600009 806600009 806600009 806600009 806600009 806600009 2 3 4 5 6 7 8 71107002 71107002 71107002 71107002 71107002 71107002 71107002 7 2 2 2 2 2 2 2 1 Tig 809 420 100109 01 100108 05 100108 07 100108 13 100108 14 100108 15 100108 16 Hex Nut 4 20 4 80860407 53 Quantity Part Number Description 2 BASE ASSEMBLY 2M 18 80860700 2Q 5 80860705 7 80860705 Self Tapping Screw Hex Cap 2R 5 46 18 x 1 1 4 4 80860717 zx o2 55 Quantity Part Number Description PVG 3 PVG 4 PVG 5 PVG 6 PVG 7 PVG 8 PVG 9 3 BASE ASSEMBLY 3 718070001 x 3 56 Quantity Part Number Description 4 FANICANOPY ASSEMBLY Canopy Assembly High Altitude ic 6 a Z 92 57 amp 9 a ey EN AN UNS 9 6 aV 7 asas 5 267 8 Quantity Part Number PVG 4 PVG 5 PVG 6 PVG 7 PVG 8 PVG 9 81660282 N A Key No Description PVG 3 5 BURNER ASSEMBLY Gas Valve Natural Gas Honeywell VR8204P1171 Gas Valve Natural Gas Honeywell VR8304P4496 Gas Valve LP Gas Honeywell VR8204C3015 Gas Valve LP Gas Honeywell VR8304P4280 Nipple gt NPT x Close 806600040 N A N A 81660283 81660146 N A 8166018
28. 7002 7B 60407001 7G 80407001 2 x x Key No Ke Quantity Part Number y Description j PVG 3 PVG 4 PVG 5 PVG 6 PVG 7 PVG 8 PVG 9 8 MISCELLANEOUS PARTS CARTON Z 80607001 Water Manifold Temperature Pressure Gauge 8056169 8110702 8110704 8A 8B 8 8 8F G 8 UN 4 AU J x I for ore gt 3 DIAMETER 4 DIAMETER N JIANIEIL 62 Important Product Safety Information Refractory Ceramic Fiber Product Warning The Repair Parts list designates parts that contain refractory ceramic fibers RCF RCF has been classified as a possible human carcinogen When exposed to temperatures about 1805 F such as during direct flame contact RCF changes into crystalline silica a known carcinogen When disturbed as a result of servicing or repair these substances become airborne and if inhaled may be hazardous to your health AVOID Breathing Fiber Particulates and Dust Precautionary Measures Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear 1 A National Institute for Occupational Safety and Health NIOSH approved respirator 2 Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body
29. ALVE PV MV MV PV GND LADDER DIAGRAM LEGFND R8285D CONTROL CENTER TERMINAL 24V EXTERNAL WIRING BLOWER RELAY TERMINAL 24N INTERNAL WIRING S8670E IGNITION MODULE TERMINAL 120V EXTERNAL WIRING GAS VALVE TERMINAL 120V INTERNAL WIRING LWCO JUMPER TERMINAL Figure 15 Internal Boiler Wiring Ladder Diagram 30 D System Controls and Wiring Refer to National Electric Code or Local Electric Codes for proper size and type of wire required Follow Code Use anti short bushings on all wiring passing through boiler jacket junction boxes and or control boxes Use armored cable BX over all exposed line voltage wiring If an indirect water heater is used use priority zoning except for Hydro Air Systems BW N e Single Zone Heating System Refer to Figure 16 of this manual for the electrical diagram for this type of system Set the thermostat heat anticipator to 0 60 amps 6 Single Zone Heating System with Alliance Water Heater Refer to Figure 17 of this manual for the electrical diagram for this type of system Set the thermostat heat anticipator to 0 60 amps 7 Conventional Circulator Zoned System Refer to Figure 18 of this manual for the electrical diagram for this type of system Read understand and follow all of the instructions provided with the Honeywell R8888 control Connect the thermostat of each zone and the circ
30. CE In order to assure prompt warranty service the owner is requested to complete and mail the attached Warranty Card within ten days after the installation of the boiler although failure to comply with this request will not void the owner s rights under these warranties Upon discovery of a condition believed to be related to a defect in material or workmanship covered by these warranties the owner should notify the installer who will in turn notify the distributor If this action is not possible or does not produce a prompt response the owner should write to U S Boiler Co Inc Burnham Hydronics at P O Box 3079 Lancaster PA 17604 giving full particulars in support of the claim The owner is required to make available for inspection by U S Boiler Co Inc or its representative the parts claimed to be defective and if requested by U S Boiler Co Inc to ship these parts prepaid to U S Boiler Co Inc at the above address for inspection or repair In addition the owner agrees to make all reasonable efforts to settle any disagree ment arising in connection with a claim before resorting to legal remedies in the courts THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE Burnham Hydronics 03 03
31. Fab Inc Saf T Vent 800 772 0739 Flex L International Inc Star 34 800 561 1980 Z Flex U S Inc Z Vent 800 654 5600 and Protech Systems Inc FasNSeal 800 766 3473 or equivalent The use of these alternate manufacturer s venting systems will require adapters to connect to the Burnham supplied vent connector and vent terminal These adapters are not supplied with this unit and should be obtained from the supplier of the alternate manufacturer s venting system See Table 3 for complete list of Burnham Vent System Components Horizontal vent pipe must maintain a minimum inch per foot slope away from boiler Use noncombustible inch pipe strap to support horizontal runs and maintain vent location and slope while preventing sags in pipe Do not restrict thermal expansion or movement of vent system Maximum support spacing is five 5 feet Do not penetrate any part of the vent system with fasteners Vent length restrictions are based on equivalent length of vent pipe total length of straight pipe plus equivalent length of fittings Maximum vent lengths are listed in Table 4 Do not exceed maximum vent lengths Table 3 lists equivalent lengths for fittings Do not include vent terminals in equivalent feet calculations Provide and maintain vent pipe minimum clearances to combustible materials Vent pipe minimum clearance to combustible material 1s four 4 inches when vent is installed in a ful
32. INSTALLATION OPERATING AND SERVICE INSTRUCTIONS FOR PVG GAS FIRED BOILER ER W ENERGY STAR As an ENERGY STAR Partner Burnham Hydronics has determined that the PVG Series meets the ENERGY STAR guidelines for energy efficiency established by the United States Environmental Protection Agency EPA For service or repairs to boiler call your heating contractor When seeking information on boiler provide Boiler Model Number and Serial Number as shown on Rating Label Boiler Model Number Boiler Serial Number Installation Date PVG Heating Contractor Phone Number Burnham Hydronics U S Boiler Company Inc 8140708R8 8 08 Price 5 00 IMPORTANT INFORMATION READ CAREFULLY NOTE The equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made These regulations shall be carefully followed in all cases Authorities having jurisdiction shall be consulted before installations are made All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and or local regulations All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and or local regulations The New York City Department of Buildings has approved the PVG Series boiler Approval No MEA 5 06 E Vol II The City of New York requires a Licensed Master Plumber supervis
33. IS PILOT BURNER ORIFICE NO BLOCKED YES CLEAN OR REPLACE PILO BURNER ORIFICE NO CONTACT GAS SUPPLIER YES REPLACE GAS VALVE CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE CLEAN FLAME ROD CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND IGNITION MODULE CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR CHECK PILOT FLAME SEE FIGURE 27 IF CHECKS OKAY REPLACE IGNITION MODULE NO NO 24VOLTS ACROSS GAS VALVE TERMINALS AND MV PV YES REPLACE GAS VALVE 24 VOLTS ACROSS IGNITION MODULE TERMINALS MV AND MV PV YES REPAIR OR REPLACE WIRES No REPLACE IGNITION MODULE NO ALLOW SYSTEM TEMPERATURE TO FALL BELOW LIMIT TEMPERATURE LESS TIN IMT CETT CUT IN TEMPERATURE OR INCREASE LIMIT CUT IN TIN YES CAUTION CONTINUITY ACROSS FLAME REPLACE FLAME ROLLOUT SWITCH DETERMINE CAUSE OF EXCESSIVE TEMPERATURE ROLLOUT SWITCH FRS BLOCKED FLUE EXCESSIVE RATE CAUSED BY HIGH MAINIFOLD PRESSURE OR OVERSIZED ORIFICES PRESSURE SWITCH FAILURE ETC BEFORE PLACING BOILER IN OPERATION 120 VOLTS ACROSS NO PROVIDE POWER TO TRANSFORMER BLACK BOILER YES 24 VOLTS AT R8285D RELAY COIL YES 24 VOLTS ACROSS TRANSFORMER BLUE AND YELLOW WIRES AND WHITE WIRES REPLACE THERMOSTAT REPLACE TRANSFORMER AFTER CHECKING FOR AFTER CHECKING FOR BROKEN WIRES AND BROKEN WIRES AND LOOSE CONNECTIONS LOOSE CONNECTIONS E NO
34. Ieui u yl 3 3 4 YI 0939 Y SIN3W3030009V3 S31 YNOd 3 122 2501 SNION NV Y INVN3ANOO OMY 8 JYNFINSdNS NO 31v93 NOILO3S SYNSLONGNOD 530 YISNUN 035 38 TIYHS 4 172 2 501 19 31 30 3301V33dN31 OMY 81 40 3215 WOWINIA V SNIAVH WINSLYN 831108 IHL OL 1314 9NILO3NNOO N3HM 3univ34 39snd38d WNWININ SQNOO3S 0 31nQOW HUM Q3Ovid3M 38 AINO NYO 3 304985 TI3MA3NOH 72 IN3WWAInO3 30 Nn 35 39v1dW3M 3813 100 li33VddV 93AV 8003 SHNSLONGNOD 530 NN IS 4N3IVAInO3 51 33IM Q3Ovid3N 38 ISAW Q30vid3N 38 15 JONVMdd JHL HUM 0319905 SV YIM TWNISINO JHL 30 ANY L SILON 3AWA Sv9 18 LAN r Fa Ad N rr I ug a TINTON 301985 L Pise L J 10114 81870 TI3MA3NOH 544 HOLMS 110 7104 78 I poe 22084 TI3MA3NOH AYI3H N3MO1 8 193NNOOSIQ 791193713 NOLWINSNI 8 1 9 002 35 45 3dAL 81 009 9 5 TYIN3NUNOO 2 05 318 2 YOSN3S NOILIND TI3M3NOH e e 3dAL 9 3215 39VL10A WMV M3L NO ML 3dAL OMY 81 3ZIS 3 INN
35. PILOT BURNER ORIFICE iS NOT BLOCKED CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE ANO PILOT OPERATOR ON GAS CONTROL CHECK FOR 24 VAC ACROSS PV MV PV TERMINALS ON MODULE IF VOLTAGE IS OKAY REPLACE GAS CONTROL IF NOT REPLACE MODULE NOTE IT MAY BE NECESSARY TO RECYCLE THE CALL FOR HEAT TO CLEAR THE PILOT SUPPLY TUBES OF AIR YES NOTE IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY RESET THE CALL FOR HEAT CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE CLEAN FLAME ROD SPARK CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD MODULE STOPS WHEN S CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR PILOTS CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE ADJUST PILOT FLAME IF PROBLEM PERSISTS REPLACE MODULE YES MAIN BURNER V qo CHECK FOR 24 VAC ACROSS PV MV PV TERMINALS ON MODULE iF NO VOLTAGE REPLACE MODULE LIGHTS CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND CAS CONTROL iF OKAY REPLACE GAS CONTROL NOTE IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY RESET THE FOR HEAT CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE NOTE GROUND IS POOR OR ERRATIC SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE ADJUST PILOT FLAME IF CHECKS ARE OKAY REPLACE MODULE CALL FOR HEAT ENDS CHECK FOR PROPER THERMOSTAT CONTROLLER OPERATION
36. areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystalline silica are not classified as hazardous wastes in the United States and Canada First Aid Procedures f contact with eyes Flush with water for at least 15 minutes Seek immediate medical attention if irritation persists If contact with skin Wash affected area gently with soap and water Seek immediate medical attention if irritation persists If breathing difficulty develops Leave the area and move to a location with clean fresh air Seek immediate medical attention if breathing difficulties persist Ingestion Do not induce vomiting Drink plenty of water Seek immediate medical attention 63 Limited Warranty FOR RESIDENTIAL CAST IRON WATER BOILERS Subject to the terms and conditions set forth below U S Boiler Co Inc Lancaster Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade water boiler manufactured and shipped on or after July 1 1991 ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE WATER BOILERS U S Boiler Co Inc warrants to the original owner that its residential grade water boilers comply at the time of manufacture with recognized hydronic industry standards and requirements then in effect
37. at minimum five 5 foot intervals and must not sag 5 All vent joints must be secure and watertight 6 joints must be secure and airtight Horizontal vent tee drain or vertical vent tee drain 1f used must have minimum 6 inch trap and allow condensate to flow freely To Clean a Disconnect drain tube from drain fitting b Flush drain tube with water Fill trap with water c Securely fasten drain tube to drain fitting providing gas tight and watertight seal 7 lf pipe must be disassembled for removal of obstructions or resealing of joint see Section III Paragraph C D Boiler Flue Passages Inspect for blockage or soot accumulation 1 Remove Main Burners See Figure 30 a Remove front door b Disconnect pilot tubing and pilot lead wires at the gas valve c Remove wires to Flame Roll out Switch d Remove Burner Access Panel e Mark location of Main Burner with Pilot Bracket on gas manifold f Hold Main Burner on throat Lift front of burners to clear orifice Burner which holds pilot can be removed by lifting the burner adjacent to its right first Disconnect Vent Connector and Vent Pipe from Blower Outlet 3 Remove Jacket Top Panel 4 Disconnect the Black and Gray Silicone Tubing 10 11 12 13 14 15 GRAY PRESSURE SWITCH from the Canopy Disconnect Wiring Harness from Blower Motor Remove Canopy Blower Assembly a Loosen the 4 screws from Canopy Remove
38. between wall ceiling joints between wall panels at plumbing and electrical penetrations and at other openings 5 For boiler located in an unconfined space in a building of other than unusually tight construction adequate combustion and ventilation air is normally provided by fresh air infiltration through cracks around windows and doors 6 For boiler located within unconfined space in building of unusually tight construction or within confined space provide outdoor air through two permanent openings which communicate directly or by duct with the outdoors or spaces crawl or attic space s of sufficient volume such that combined freely communicating with the outdoors Locate one volume of all spaces meet criteria for unconfined opening within twelve 12 inches of top of space space Size each opening for minimum free area Locate remaining opening within twelve 12 inches of one 1 square inch per 1 000 Btu per hour of bottom of space Minimum dimension of air input of all equipment in spaces but not less than opening is three 3 inches Size each opening per 100 square inches following 7 Combustion Air Ventilation Duct Louvers and a Direct communication with outdoors Minimum Grilles Equip outside openings with louvers to free area of one 1 square inch per 4 000 Btu per prevent entrance of rain and snow and screens to hour input of all equipment in space prevent entrance of insects and rodents Louvers and b Vertical
39. bustion and ventilation air in accordance with applicable provisions of local building codes or USA National Fuel Gas Code NFPA 54 ANSI Z223 1 Air for Combustion and Ventilation Canada Natural Gas or Propane Installation Code CAN CSA B149 1 WARNING Adequate combustion and ventilation air must be provided to assure proper combustion The following guideline is based on the National Fuel Gas Code NFPA 54 ANSI Z223 1 1 Determine volume of space boiler room Rooms communicating directly with space through openings not furnished with doors are considered part of space Volume ft Length ft x Width ft x Height ft 2 Determine Total Input of all appliances in space Round result to nearest 1 000 Btu per hour Btuh 3 Determine type of space Divide Volume by Total Input a Ifresult is greater than or equal to 50 ft per 1 000 Btuh space is considered an unconfined space b If result is less than 50 ft per 1 000 Btuh space is considered a confined space 4 Determine building type A building of unusually tight construction has the following characteristics a Walls and ceiling exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and sealed and b Weather stripping has been added on openable windows and doors and c Caulking or sealants applied in joints around window and door frames between sill plates and floors
40. cated in air handling units where they may be exposed to refrigerated air boiler piping must be equipped with flow control valves to prevent gravity circulation of boiler water during operation of cooling system WATER _ T CHILLER lt L HEATING BOILER Cc SHUT OFF VALVES I RETURN MAIN FROM COMBINED G amp COOLING SYSTEM Figure 10 Recommended Piping for Combination Heating amp Cooling Refrigeration System I Use a boiler bypass if the boiler is to be operated in a system which has a large volume or excessive radiation where low boiler water temperatures may be encountered i e converted gravity circulation system etc 21 22 PRESSURE RELIEF VALVE OUTLET WATER MANIFOLD TO SYSTEM SUPPLY TEMPERATURE PRESSURE GAUGE Figure 10A Supply Water Manifold Piping Install pipe tee between circulator and boiler return along with second tee in supply piping as shown in Figure 11 or 12 Bypass should be same size as the supply and return lines with valves located in bypass and supply outlet as illustrated in Figure 11 or 12 in order to regulate water flow to maintain higher boiler water temperatures After the boiler is operational reference Section VIII System Start Up set by pass and boiler supply valves to half throttle position to start Operate boiler until system water temperature reaches normal operating range Adjust valves to provide 180 to 200 F supply water tem
41. d position E Tilt the boiler to its front side or back side and slide a B Remove all crate fasteners wooden slat under the three raised feet C Lift and remove outside container Save two of the F Tilt the boiler in the opposite direction and slide wooden slats from the container sleeve for use in Steps another wooden slat under the three raised feet E and F G Slide the boiler left or right off the skid using the two D Remove all boiler hold down fasteners wooden slats as runners H Move boiler to its permanent location Ill Venting WARNING Do not use this boiler with galvanized Type 304 or Type 316 stainless steel non metallic or any other non AL29 4C based vent systems Do not use a barometric damper or drafthood with this appliance Do not use vent dampers with this boiler Moisture and ice may form on surfaces around termination To prevent deterioration surfaces should be in good repair sealed painted etc This appliance needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air Read understand and follow combustion air instruction restrictions contained in the Pre Installation instructions of this manual Do not operate appliance where gasoline or other flammable vapors or liquids or sources of hydro carbons i e bleaches cleaners chemicals sprays paint removers fabric softeners etc are used stored and or present in the air W
42. ducts Minimum free area of one 1 grilles must be fixed in open position or interlocked square inch per 4 000 Btu per hour input of all with equipment to open automatically before burner equipment in space Duct cross sectional area operation Screens must not be smaller than inch shall be same as opening free area mesh c Horizontal ducts Minimum free area of one 1 Consider the blocking effect of louvers grilles and square inch per 2 000 Btu per hour input of all screens when calculating the opening size to provide equipment in space Duct cross sectional area the required free area If free area of louver or grille shall be same as opening free area 15 not known assume wood louvers have 20 25 percent free area and metal louvers and grilles have 60 75 percent free area Alternate method for boiler located within confined space Use indoor air if two permanent openings communicate directly with additional CAUTION Avoid operating this boiler in an environment where saw dust loose insulation fibers dry wall dust etc are present If boiler is operated under these conditions the burner interior and ports must be cleaned and inspected daily to insure proper operation Il Unpack Boiler CAUTION WARNING Do not drop boiler Do not bump boiler jacket Installation of this boiler should be undertaken against floor only by trained and skilled personnel from a qualified service agency A Moveboiler to approximate installe
43. e provided with the boiler before installing starting up operating maintaining or servicing Keep boiler area clear and free from combustible materials gasoline and other flammable vapors or liquids All cover plates enclosures and guards must be in place at all times NOTICE This boiler has a limited warranty a copy of which is printed on the back of this manual It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete Table of Contents I Pre Installation 6 Unpack Boiler 7 HI Venting 8 IV Water Piping and Trim 20 V GasPiping 25 VI Electrical sessa 2S VII Modular Installation 37 System Start up 39 IX Service 46 X Repair Parts 52 VENT SEE NOTE 3 N 2 7 E 6 SEE NOTE 4 58 09 NOTES VENT 1 SEE NOTE 3 TN Z SEE NOTE 1 VENTILATION AIR INLET OPENINGS SEE NOTE 2 CLOSET DOOR VENTILATION AIR INLET OPENINGS SEE NOTE 2 FLOOR LINE 2 fe 1 VENT PIPE MINIMUM CLEARANCE TO COMBUSTIBLE MATERIAL IS FOUR 4 INCHES WHEN VENT IS INSTALLED IN A FULLY ENCLOSED CHASED
44. e the installation of this product The Massachusetts Board of Plumbers and Gas Fitters has approved the PVGTM Series boiler See the Massachusetts Board of Plumbers and Gas Fitters website http license reg state ma us pubLic pb pre form asp for the latest Approval Code or ask your local Sales Representative The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning product life DANGER CAUTION Indicates an imminently hazardous situation Indicates a potentially hazardous situation which which if not avoided will result in death serious if not avoided may result in moderate or minor injury or substantial property damage injury or property damage WARNING NOTICE Indicates a potentially hazardous situation which Indicates special instructions on installation if not avoided could result in death serious injury operation or maintenance which are important or substantial property damage but not related to personal injury hazards DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance If you smell gas vapors NO NOT try to operate any appliance DO NOT touch any electrical switch or use any phone in the building Immediately call the gas supplier from a r
45. ed to avoid a pressure loss due to the escape of air trapped in the boiler To perform a long term pressure test including the boiler ALL trapped air must first be removed from the boiler A loss of pressure during such a test with no visible water leakage is an indication that the boiler contained trapped air 1 Close full port ball valve in boiler supply piping 2 Isolate all zones by closing zone valves or shut off valves in supply and return of each zone s 3 Attach a hose to the vertical hose bib located prior to the full port ball valve in the system supply piping Note Terminate hose in five gallon bucket at a suitable floor drain or outdoor area 4 Starting with one circuit at a time open zone valve or shut off valve in system supply and return piping 5 Open hose bib 6 Open fill valve Make up water line should be located directly after full port ball valve in system supply piping between air scoop and expansion tank 7 Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds 8 Close the opened zone valve or shut off valve for the zone being purged of air then open the zone valve or shut off valve for the next zone to be purged Repeat this step until all zones have been purged At completion open all zone valves or shut off valves 9 Close hose bib continue filling the system until the pressure gauge reads 12 psi Close fill valve Note If
46. emotely located phone Follow the gas supplier s instructions or if the supplier is unavailable contact the fire department WARNING This boiler requires regular maintenance and service to operate safely Follow the instructions contained in this manual Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Read and understand the entire manual before attempting installation start up operation or service Installation and service must be performed only by an experienced skilled and knowledgeable installer or service agency This boiler must be properly vented This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air The interior of the venting system must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions A clean and unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler s efficiency Installation is not complete unless a pressure relief valve is installed into the tapping located on top of appliance See the Water Piping and Trim Section of this manual for details This boiler is supplied with safety devices which may cause the boiler to shut down and not re start
47. es open flames or be disconnected from gas supply piping For testing other ignition source to check for leaks 27 VI Electrical DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building Lock out all electrical boxes with padlock once power is turned off WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm Electrical power may be from more than one source Make sure all power is off before attempting any electrical work Each boiler must be protected with a properly sized over current device Never jump out or make inoperative any safety or operating controls The wiring diagrams contained in this manual are for reference purposes only Each boiler is shipped with a wiring diagram attached to the front door Refer to this diagram and the wiring diagram of any controls used with the boiler Read understand and follow all wiring instructions supplied with the controls A General Install wiring and electrically ground boiler service switch such that the boiler can be shut off in accordance with authority having jurisdiction or in without exposing personnel to danger in the event of the absence of such requirements follow the National an emergency Connect the main power supply and Electrical Code NFPA 70 and or CSA C22 1 Electrical ground to the three 3
48. es dl wali 3215 3NYS N 3 00SS33d 323H2 1MOd 1113 1MOd 1113 Pd Pd 3ATVA ve 3ATVA Tiv8 T JAVA 3NOZ NO eec av SOON _ Em 81 1N3A OL 4009 gla 38 VIII System Start up A Safe operation and other performance criteria were met with gas manifold and control assembly provided on boiler when boiler underwent tests specified in American National Standard for Gas Fired Low Pressure Steam and Hot Water Boilers ANSI Z21 13 Verify that the venting water piping gas piping and electrical system are installed properly Refer to installation instructions contained in this manual Confirm all electrical water and gas supplies turned off at the source and that vent is clear of obstructions 5 Confirm that all manual shut off gas valves between the boiler and gas source are closed WARNING Completely read understand and follow all instructions in this manual before attempting start up E Fill entire heating system with water and vent air from system Use the following procedure on a Series Loop or multi zoned system installed as per Figure 11 or 12 to remove air from system when filling WARNING The maximum operating pressure of this boiler is 30 psig Never exceed this pressure Do not plug or change pressure relief valve NOTICE If it is required to perform a long term pressure test of the hydronic system the boiler should first be isolat
49. h gloves before installing Seal joint with RTV specified in this manual C Install Vent Pipe Burnham Gasketed Vent System 1 Procedure for Joining Burnham Gasketed Vent Pipe and Fittings See Figure 3 a Wipe the male end of each joint using an alcohol pad to remove any dirt and grease b Align weld seams in pipes and use a slight twisting motion to FULLY insert male end into female end of joint Ensure bead in male end of pipe is below locking band and rest against the end of the female pipe Verify the factory installed gasket is not dislodged or cut FEMALE BELL END VE MALE BEAD END GASKETED VENT SYSTEM LOCKING BAND TIGHTEN BY HAND WITH NUT TOWARD BOILER DRIVER UNTIL SNUG PLUS 1 TURN DO NOT USE SHEET METAL SCREWS TO SECURE JOINTS Figure 3 Burnham Gasketed Vent Joint Detail 11 c Tighten locking band by HAND with a 5 16 nut driver until snug plus 1 4 turn DO NOT SECURE JOINTS WITH SHEET METAL SCREWS OR POP RIVETS DO NOT PUNCTURE THE VENT SYSTEM d Once the installation is complete operate appliance and inspect all Joints to ensure that flue gases and or liquid condensate will not escape D Horizontal Venting System See Figures 4 4A and 5 12 Vent Piping 1 This boiler is supplied with components as standard equipment for installation of the separate horizontal venting system Do not exceed maximum vent lengths Refer to Table 4
50. he 4 Corrections for the specific gravity of natural gas boiler or structure Always assure gas piping is can be found in Table 6 absolutely leak free and of the proper size and type for the connected load Table 6 Specific Gravity Correction Factors for An additional gas pressure regulator may be Natural Gas needed Consult gas supplier A Size gas piping Design system to provide adequate gas Gravity Factor Gravity Factor supply to boiler Consider these factors j 1 Allowable pressure drop from point of delivery to gt 090 0 82 boiler Maximum allowable system pressure is 0 60 100 psig Actual point of delivery pressure may be less 06 0 contact gas supplier for additional information Minimum gas valve inlet pressure 1s stamped on the rating label located in the boiler s vestibule 075 090 compartment 1 os 2 Maximum gas demand Refer to the boiler s input as printed on its rating label Also consider existing and expected future gas utilization equipment i e water For materials or conditions other than those listed heater cooking equipment above refer to National Fuel Gas Code NFPA54 ANSI 7223 1 or size system using standard engineering methods acceptable to authority having jurisdiction 3 Length of piping and number of fittings Refer to Table 5 Gas Ratings Boiler Natural LP Minimum Natural Minimum LP Natural LP Model Maximum Gas Pressu
51. heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS gt Do not try to light any appliance gt Do not touch any electric switch do not use any phone in your building gt Immediately call your gas supplier from a neigh bor s phone Follow the gas supplier s instructions C If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life gt If you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety information above on this label Setthe thermostat to lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Remove front door GAS CONTROL KNOB Locate the gas control valve at the end of the gas supply pipe going into the boiler The gas control knob i
52. hen installing vent pipe through chimney no other appliance can be vented into the chimney Do not exceed maximum vent lengths Refer to Table 4 Table 1 Vent System Options Additional instalation Option Description Vent Kit inga Specification Required See Section Power Vent air from within building the vent pipe terminates horizontally through a sidewall Power Vent air from within building the vent pipe terminates 2 Vertical 4 vertically through the roof 1 Horizontal Table 2 Vent System Components Included with Boiler Vent System Components Part Number Gasketed Vent Terminal 3 Horizontal PVG 3 thru PVG 7 8110701 Gasketed Vent Terminal 4 Horizontal PVG 8 amp PVG 9 8110702 Table 3 Burnham Vent System Components Equivalent Vent System Component Part Number Feet of Pipe 3 Dia Pipe x 1 Ft 4 Dia Pipe x 1 Ft 3 Dia Pipe x 3 Ft 4 Dia Pipe x 3 Ft 3 Dia Pipe x 5 Ft 4 Dia Pipe x 5 Ft 100178 01 3 Dia Pipe x Adjustable 8116319U Equal to Installed Length 4 Dia Pipe x Adjustable 1 06 TO 1 64 3 Dia 90 Elbow S amens a 3 Double Wall Thimble 8116115 4 Double Wall Thimble 100185 01 Table 4 Vent Length 3 Vent Pipe 4 Vent Pipe Model Equiv Ft Equiv Ft PVG 3 amp PVG 4 PVG 5 amp PVG 6 PVG 7 PVG 8 amp PVG 9 A 10 Vent Guidelines Due to Removal of an Existing Boiler For installations not involving the replacement
53. ic Ignition Modules with LED indicators Figure 24 for Troubleshooting Guide Table 10 cross references the ignition module terminal designations to the ignition terminal m n Table 10 Ignition Module Terminal Cross Reference Ignition Module Wiring Ladder Diagram Terminal Designation Terminal Number MV 24V 6500M Continuous Retry DA Wr PASA Mac 10 Sec le 24V GND Ja FLAME LED STATUS LED M23440 Figure 23 LED Locations TABLE 11 Yellow LED Flame Codes Yellow LED Heartbeat Normal Flame Signal Weak Flame Signal System will operate reliably but flame signal is less than desired Perform routine maintenance to Note This indication may flash temporarily assure optimum flame signal during or shortly after lightoff on some appli cations m Marginal Flame Signal less than 1 1 pA System may not operate reliably over time Check gas supply pilot burner flame sense wiring contamination of flame rod burner ground connection Service call recommended Note This indication may flash temporarily during or shortly after lightoff on some appli cations 2 1 No Flame or Flame Signal OFF Below minimum threshold for system opera tion Flash Code Descriptions Heartbeat Constant gt second bright gt second dim cycles The flash code number signifies that the LED flashes X times at 2Hz remains off for two second
54. ice Years In Service dx Service Charge as of 65 Retail Price NOTE If the heat exchanger model involved is no longer available due to product obsolescence or redesign the value used to establish the retail price will be the published price as shown in the Burnham Hydronics Repair Parts Price Sheet where the heat exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger ADDITIONAL TERMS AND CONDITIONS 1 Applicability The limited warranties set forth above are extended only to the original owner at the original place of installation within the United States and Canada These warranties are applicable only to water boilers designated as residential grade by U S Boiler Co Inc and installed in a single or two family residence and do not apply to steam boilers of any kind or to commercial grade boilers 2 Components Manufactured by Others Upon expiration of the one year limited warranty on residential grade water boilers all boiler components manufactured by others but furnished by U S Boiler Co Inc such as oil burner circulator and controls will be subject only to the manufacturer s warranty if any 3 Proper Installation The warranties extended by U S Boiler Co Inc are conditioned upon the installation of the residential grade water boiler in strict compliance with U S Boiler Co Inc installation instructions U S Boiler Co
55. inutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code NFPA 54 ANSI Z223 1 When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part II in the National Fuel Gas Code NFPA 54 ANSI Z223 1 B General Guidelines Vent system installation must be in accordance with National Fuel Gas Code 54 ANSI 7221 3 or applicable provisions of local building codes Contact local building or fire officials about restrictions and installation inspection in your area Refer to the appropriate drawings in this section of this manual to determine the proper configuration of venting system See Table 1 This appliance requires a Special Gas Vent The productis designed to use Burnham supplied AL29 4C Stainless Steel vent system components The following manufacturers offer similar AL 29 4 components and are approved for use with this product Heat
56. ion Figure 9 Horizontal Vent Terminal Installation 3 Vent left view or 4 Vent right view 19 IV Water Piping and Trim 20 WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or structure Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components and can lead to boiler failure Burnham s Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale lime build up caused by frequent addition of water Design and install boiler and system piping to prevent oxygen contamination of boiler water and frequent water additions 1 There are many possible causes of oxygen contamination such as a Addition of excessive make up water as a result of system leaks b Absorption through open tanks and fittings c Oxygen permeable materials in the distribution system 2 In order to insure long product life oxygen sources must be eliminated This can be accomplished by taking the following measures a Repairing system leaks to eliminate the need for addition of make up water b Eliminating open tanks from the system c Eliminating and or repairing fittings which allow oxygen absorption d Use of non permeable materials in the distribution system e Isolating the boiler from the system water by installing a heat exchanger f Use properly designed and operating air elimination devices in water piping
57. l size larger drill size is stamped on orifice or see Section X Repair Parts iii Reinstall gas orifices and main burners Measure input rate 6 Recheck Main Burner Flame 7 Return other gas fired appliances to previous conditions of use Q Review User s Information Manual and system operation with owner or operator Table 13 Gas Flow Rate in Cubic Feet Per Hour Seconds for One One Half One Two 120 o 189 180 172 164 157 NJO N ojo o 138 133 129 124 120 oo o gt 9 32 5 5 5 45 s 46 39 nr 3 5 36 5 er 3 3 5 3 L se 3 45 IX Service a 46 DANGER This boiler uses flammable gas high voltage electricity moving parts and very hot water under high pressure Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service Do not attempt any service work if gas is present in the air in the vicinity of the boiler Never modify remove or tamper with any control device WARNING This boiler must only be serviced and repaired by skilled and experienced service technicians If any controls are replaced they must be replaced with identical models Read understand and follow all the instructions and warnings contained in all the sections of this manual If any e
58. lectrical wires are disconnected during service clearly label the wires and assure that the wires are reconnected properly Never jump out or bypass any safety or operating control or component of this boiler Read understand and follow all the instructions and warnings contained in ALL of the component instruction manuals Assure that all safety and operating controls and components are operating properly before placing the boiler back in service General Inspection and service should be conducted annually Turn off electrical power and gas supply while conducting service or maintenance Follow instructions TO TURN OFF GAS TO APPLIANCE See Figure 22 Low water cutoff 1f so equipped Probe Type Annual Service Probe type LWCO should be removed once a year examined and cleaned of any dirt accumulations to assure proper operations Do not attempt to repair mechanisms in the field Complete replacement mechanisms including necessary gaskets and installation instructions are available from the manufacturer Vent System Inspect for obstructions soot accumulation proper support and deterioration of pipe fittings and joints 1 Clean terminal screens Terminals must be free of obstruction undamaged with screens securely in place 2 Terminal and wall thimbles 1f used must be weathertight 3 Pipe must be full round shape and show no damage from impact or excessive temperature 4 Pipe must be supported
59. load will result in excessive boiler cycling and accelerated component failure Burnham DOES NOT warrant failures caused by mis sized boiler applications DO NOT oversize the boiler to the system Modular boiler installations greatly reduce the likelihood of boiler oversizing A Installation must conform to the requirements of the authority having jurisdiction In the absence of such requirements installation must conform to the National Fuel Gas Code NFPA 54 ANSI Z223 1 and or CAN CSA B149 1 Installation Codes B Appliance is design certified for installation on combustible flooring Do not install boiler on carpeting a Provide clearance between boiler jacket and combustible material in accordance with local fire ordinance Refer to Figure 1 for minimum listed clearance from combustible material Recommended service clearance is 24 inches from left side right side and front Service clearances may be reduced to minimum clearances to combustible materials 5 Install on level floor For basement installation provide solid base such as concrete if floor is not level or if water may be encountered on floor around boiler Floor must be able to support weight of boiler water and all additional system components Protect gas ignition system components from water dripping spraying rain etc during boiler operation and service circulator replacement condensate trap control replacement etc F Provide com
60. ly enclosed chase application or three 3 inches when vent is installed with at least one side open similar to a joist bay application Use double wall thimble Burnham Part 8116115 37 100185 01 4 when penetrating a combustible wall Do not install venting system components on the exterior of the building except as specifically required by these instructions The vent termination location is restricted as follows 10 a Minimum twelve 12 inches above grade plus normally expected snow accumulation level or seven 7 feet above grade if located adjacent to public walkway Do not install over public walkway where local experience indicates appliance flue gas vapor or condensate creates a nuisance or hazard b Minimum three 3 feet above any forced air inlet located within ten 10 feet c Minimum four 4 feet below four 4 feet horizontally from or four 4 feet above any door window or gravity air inlet d Minimum four 4 feet horizontally from electric meters gas meters regulators and relief valves This distance may be reduced if equipment 15 protected from damage due to condensation or vapor by enclosure overhangs etc e Minimum twelve 12 inches from overhang or corner of building Enclose vent passing through occupied or unoccupied spaces above the boiler with material having a fire resistance rating of at least equal to the rating of the adjoining floor or ceiling Maintain mini
61. m diameter to prevent bridging between the probe and the tee Also the run of the tee must have a minimum diameter to prevent the end of the probe from touching or being located too close to the inside wall of the run of the tee Ideally manual shutoff valves should be located above the LWCO and the boiler to allow for servicing This will allow probe removal for inspection without draining the heating system Many probe LWCO manufacturers recommend an annual inspection of the probe How to Wire Ensure power is turned off to boiler Locate the LWCO jumper wire in the factory wiring harness Remove the jumper wire and install the LWCO wiring from LWCO Model 1100 H4 P N 100592 01 into the plug of the PVG factory wiring How to Test Shut off fuel supply Lower water level until water level is BELOW the LWCO Generate a boiler demand by turning up thermostat Boiler should not attempt to operate Increase the water level by filling the system The boiler should attempt to operate once the water level is above the LWCO NOTICE Ensure the location of the LWCO in the piping will allow for connection of the LWCO wiring harness to the factory wiring of the PVG C Connect system supply and return piping to boiler See Figures 11 and 12 Maintain minimum inch clearance from hot water piping to combustible materials NOTICE Burnham recommends sizing the system circulatorto supply sufficient flow GPM to allow a 20 F tempera
62. make up water line is equipped with pressure reducing valve system will automatically fill to 12 psi Follow fill valve manufacturer s instructions 10 Open isolation valve in boiler supply piping 11 Remove hose from hose bib Confirm that the boiler and system have no water leaks Prepare to check operation 1 Obtain gas heating value in Btu per cubic foot from gas supplier 2 Connect manometer to pressure tap on gas valve Use 1 8 NPT tapping provided 3 Temporarily turn off all other gas fired appliances 4 Turn on gas supply to the boiler gas piping 5 Confirm that the supply pressure to the gas valve is 14 in w c orless Refer to Table 5 for minimum supply pressure 6 Open the field installed manual gas shut off valve located upstream of the gas valve on the boiler 7 Using soap solution or similar non combustible solution electronic leak detector or other approved method Check that boiler gas piping valves and all other components are leak free Eliminate any leaks DANGER Do not use matches candles open flames or other ignition source to check for leaks 8 Purge gas line of air 39 FOR YOUR SAFETY READ BEFORE OPERATING WARNING A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is
63. mum clearances to combustible materials See Figure 1 Note For one or two family dwellings fire resistance rating requirement may not need to be met but is recommended Plan venting system to avoid possible contact with plumbing or electrical wires Start at vent connector on top of boiler and work towards vent terminal 11 Once a vent pipe manufacturer and system 1s chosen 12 ENSURE BEAD IN MALE END REST AGAINST END OF FEMALE PIPE never mix and match vent systems If a non standard length pipe is required Gasketed Vent System The use of the adjustable length pipe P N 8116319U is recommended to complete a non standard pipe length This pipe requires a minimum installed length of 1274 inch and can adjust across a 7 inch gap up to a maximum of 19 inch long Note for the adjustable pipe the installed length should be measured from the centerline of the bead on the male end of the first pipe to the end of the female pipe excluding the locking band of the second pipe with a single gasket Only in the event the adjustable length pipe 15 not sufficient a standard length pipe may be cut using the procedure outlined below for the Gasket Less Vent System WARNING Never exceed maximum installed length of 19 inches for adjustable length pipe Risk of flue gas leakage is possible NOTICE Cut must be square with pipe and filed or sanded smooth before joining Carefully ensure roundness of cut pipe by hand wit
64. of an existing boiler proceed to Step B When an existing boiler is removed from a common venting system the common venting system is likely to be too large for proper venting of the remaining appliances At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation 1 Seal any unused openings in the common venting system Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition Insofar as 15 practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers Place in operation the appliance being inspected Follow the Lighting or Operating Instructions Adjust thermostat so appliance will operate continuously Test for spillage at the draft hood relief opening after five 5 m
65. perature Opening the boiler supply valve will raise system temperature while opening the by pass valve will lower system supply temperature J After the boiler and system have been cleaned and flushed and before refilling the entire system add appropriate water treatment chemicals 1f necessary to bring the pH between 7 and 11 If it is required to perform a long term pressure test of the hydronic system the boiler should first be isolated to avoid a pressure loss due to the escape of air trapped in the boiler To perform a long term pressure test including the boiler ALL trapped air must first be removed from the boiler A loss of pressure during such a test with no visible water leakage is an indication that the boiler contained trapped air lddns 0109 994034 3l W31SAS S3NOZ OL 43914933 301911549 JOMINOO 140 1 5 gt NII 3NOZ L p uoz 5119 104 Buidid 1 61 3l N 3 JAVA 3 38 MOSHO 4dJO 1nHS 3unSS33d P lt _ L t lt dOOOS MIV I 1N3A 31 31 3 3ONVITIV OL ACIS LAAT 1108 JO 30013 30 9 NIHLIM SAWA 59134 350553359 AlddNS W31SAS 1139 W3lSAS XNVL NOISNVdX3
66. re Gas Pressure Manifold Manifold Number Gas Pressure in w c in w c Pressure Pressure in w c Inlet to Gas Valve Inlet to Gas Valve in w c in w c NOTICE PVG boilers built for altitudes greater than 4 999 feet above sea level need to be specially orificed to adjust for changes in atmospheric conditions The PVG boiler H Model has been certified to operate in atmospheric conditions from 5 000 to 10 000 feet above sea level Input is derated by 10 for applications at 5 000 feet above sea level and 20 for applications at 10 000 feet above sea levels Derate is based on 2 reduction per 1000 feet The PVG boiler is available in two 2 altitude Models The S Model 0 to 4 999 feet above sea level and the H Model 5 000 to 10 000 feet above sea level For applications above 10 000 feet consult the manufacturer 25 Table 7 Maximum Capacity of Schedule 40 Pipe in CFH For Natural Gas Pressures of 0 5 psig or Less Length 0 3 inch w c Pressure Drop 1 of Natural Gas is approximately equal to 1 MBH 1 of LP is approximately equal to 2 5 MBH con tact your gas supplier for the actual heating value of your gas B Connectboiler gas valve to gas supply system 2 Use thread joint compounds pipe dope resistant to action of liquefied petroleum gas WARNING 3 Install sediment trap ground joint union and manual shut off valve upstream of boiler gas control valve Failure to use proper
67. s and then repeats sequence 41 Table 12 Green LED Status Codes Green LED Flash Code Indicates X Y No Call for Heat Flash Fast Startup Flame sense calibration Heartbeat Normal operation Next System Action Recommended Service Action 5 minute Retry Delay Pilot flame not detected during trial for ignition Recycle Flame failed during run Flame sensed out of sequence Low secondary voltage supply below 15 5 Vac 5 minute Retry Delay On every third retry on same Call for Heat On every 6th flame failure during run on the same Call for Heat Flame sensed out of sequence longer than 10 seconds 6 6 6 Flame sense leakage to ground 2 3 4 7 2 3 4 Soft lockout due to error ON detected during self check sequences aFlash Code Descriptions Flash Fast rapid blinking Initiate new trial for ignition after retry delay completed Initiate new trial for ignition Flash code will remain through the ignition trial until flame is proved If situation self corrects within 10 seconds control returns to normal sequence If flame out of sequence re mains longer than 10 seconds control goes to Flash code 6 4 see below Control remains in wait mode When the fault corrects control resumes nor mal operation after a one minute delay Control remains in wait mode When the fault corrects control resumes nor mal operation after one minute delay Ini
68. s from roof surface Allow additional vertical distance for expected snow accumulation Provide brace as required Refer to Figure 8 Install storm collar on vent pipe immediately above flashing Apply Dow Corning Silastic 732 RTV Sealant between vent pipe and storm collar to provide weathertight seal Attach vent terminal Jesyo WV ain6ld AVE 1510 V OL YVIINIS N3dO 3015 JNO 1SV31 LY Q3TIVISNI SI LN3A N3HM S3HONI 338 YO 3SvHO Q3S019N3 V NI Q3TIVISNI SI INJA N3HM S3HONI v 3n04 SI 31811508WO9 OL JONVYVSIO AnNAININ 3414 INJA 5 1134 TWNOILIGGY 9 38 9 33S NOILVINSNI 431108 GYVMOL 1003 Yad v L NMOQ SNNY WLNOZIYOH ONIOWdS 714 S SNIHSY13 dVMIS amp 511130 8 34n9lJ4 33S TVNINS3L IN3A uonejejsuj JU A 9 4 31VSN3GQNOO 331 LIN3A WOLLYSA YOddNS 0153 14 90153313 SNIHSV 14 51 13 TWNOILIGGV 0 8 330914 33S ACIS LAAT Svo 3014 3 OL 35012 dVMIS v NOLLYINSNI 31 NOILVINSNI WNINYSL LN3A 17 MOUS Sugp sip X Jeuonippe JNS WOJ 59191 ZL JO o2uejsip A Iejuoziiou pue X e9437
69. s the brown or blue plastic knob located on top of the gas control valve 7 Rotate gas control knob clockwise CY from ON position to OFF Make sure knob rests against stop Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you do not smell gas go to the next step Rotate gas control knob counterclockwiseY from OFF to ON Make sure knob rest against stop Do not force Replace front door Turn on all electric power to the appliance Set thermostat to desired setting If the appliance will not operate follow the instructions TO TURN OFF GAS TO APPLIANCE and call your service technician or gas supplier Setthe thermostat to lowest setting Turn off all electric power to the appliance if service is to be performed 3 Remove front door 4 5 Rotate gas control knob clockwise CN from ON position to OFF Make sure knob rests against stop Replace front door Figure 22 Operating Instructions 40 H Operating Instructions 1 Follow Operating Instructions to place boiler in operation See Figure 22 numbers in the wiring ladder diagrams The yellow LED indicates the status of the flame see Table 11 The green LED indicates the status of the system see Table 12 See Figure 23 for LED locations See 2 Electron
70. sequential damages of any kind whatsoever under these warranties including but not limited to injury or damage to persons or property and damages for loss of use inconvenience or loss of time U S Boiler Co Inc liability under these warranties shall under no circumstances exceed the purchase price paid by the owner for the residential grade water boiler involved Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you 8 Limitation of Warranties These warranties set forth the entire obligation of U S Boiler Co Inc with respect to any defect in a residential grade water boiler and U S Boiler Co Inc shall have no express obligations responsibilities or liabilities of any kind whatsoever other than those set forth herein These warranties are given in lieu of all other express warranties ALL APPLICABLE IMPLIED WARRANTIES IF ANY INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES IF ANY APPLICABLE TO THE HEAT EXCHANGER IN A RESIDENTIAL GRADE WATER BOILER SHALL EXTEND TO THE ORIGINAL OWNER FOR THE LIFETIME OF THE ORIGINAL OWNER AT THE ORIGINAL PLACE OF INSTALLATION SOME STATES DO NO ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU PROCEDURE FOR OBTAINING WARRANTY SERVI
71. t up G Procedure for measuring differential pressure See Figure 31 1 With boiler off remove Gray and Black Hoses at differential pressure switch 2 With tees and inch aluminum stubs connect water manometer as shown with additional tubing 47 Jeuung 3noue lS 1euung an 4 0 eJnDiJ S3N3n8 3 YSNYNE 13315 9593 1 5 318VAOW3M HSnag 37115109 1405 55222 YANYNE T3NVd 13 9VfP 3004 3 18VAOW3M iINOd4 AdONVO NI 3013 TANVd dOl Layover Table 14 Pilot Burner Location Main burners numbered left to right as viewed from front of boiler 3 Start boiler and read Pressure on Manometer when boiler water temperature reaches operating temperature Refer to Table 15 for minimum readings NOTE If switch drops out before boiler reaches temperature or if pressure differential readings are below minimums shown in Table 15 check for cracks in hose or contact your nearest Burnham representative 4 Stop boiler remove manometer and reconnect hoses to differential pressure switch See Figures 28 and 31 Figure 31 Differential Pressure Measurement Table 15 Differential Pressure Switch Settings Minimum Differential Pressure Sea Level to 4 999 Ft 5 000 10 000 Ft Elevation Boiler Model 49 SPARK PRESENT NO AT PILOT IGNITOR SENSOR YES DISCONNECT IGNITOR SENSOR CABLE FROM IGNITION MODULE TERMINAL
72. thread compounds on all and outside jacket See Figure 13 gas connectors may result in leaks of flammable TP gas T GROUND JONN TEE WARNING Be Gas supply to boiler and system must be A 1 3 absolutely shut off prior to installing or servicing boiler gas piping Use methods and materials in accordance with local plumbing codes and requirements of gas supplier In absence of such requirements follow National Fuel Gas Code NFPA 54 ANSI Z223 1 H Figure 13 Recommended Gas Piping Table 8 Equivalent Lengths of Standard Pipe Fittings amp Valves Through un Through rane os o ws os 43 16 we 91 a 1 6 1 v 100 os 224 uz 68 26 25 35 160 26 4 Allabove ground gas piping upstream from manual at 4 psig or less isolate boiler from gas supply psig shut off valve must be electrically continuous and piping by closing boiler s individual manual shutoff bonded to a grounding electrode Do not use gas valve piping as grounding electrode Refer to National 2 Locate leaks using approved combustible gas Electrical Code NFPA 70 detector soap and water or similar nonflammable C Pressure test The boiler and its gas connection must solution be leak tested before placing boiler in operation DANGER 1 Protect boiler gas control valve For all testing over psig boiler and its individual shutoff valve must Do not use matches candl
73. tiate new trial for ignition after retry delay completed 5 minute retry delay then initiate new trial for ignition Control waits until flame is no longer sensed and then goes to soft lockout Flash code continues Control auto resets from soft lockout after one hour Control auto resets from soft lockout after one hour Heartbeat Constant 75 second bright gt second dim cycles Asingle flash code number signifies that the LED flashes X times at 2Hz remains off for two seconds and then repeats the sequence If system fails to light on next trial for ignition check gas supply pilot burner spark and flame sense wir ing flame rod contamination or out of position burner ground connec tion If system fails to light on next trial for ignition check gas supply pilot burner flame sense wiring flame rod contamination burner ground connection Check for pilot flame Replace gas valve if pilot flame present If no pilot flame cycle Call for Heat If error repeats replace control Check flame sense lead wire for damage or shorting Check that flame rod is in proper position Check flame rod ceramic for cracks damage or tracking Check transformer and AC line for proper input voltage to the control Check with full system load on the transformer Check gas supply pilot burner spark and flame sense wiring flame rod contamination or out of position burner ground connection Check gas supply pilot
74. ture differential in the system When sizing the system circulator the pressure drop of all radiators baseboard and radiant tubing and all connecting piping must be considered D Install circulator with flanges gaskets and bolts provided Circulator harness allows circulator to be mounted on supply or return Connect harness to circulator and secure any excess conduit E Installsupply manifold pressure temperature gauge and pressure relief valve See Figure 10A Pressure Relief Valve must be installed with spindle in vertical position Installation of the relief valve must comply with the ASME Boiler and Pressure Vessel Code Section IV WARNING Pressure relief valve discharge piping must be piped such that the potential of severe burns is eliminated DO NOT pipe in any area where freezing could occur DO NOT install any shut off valves plugs or caps Consult Local Codes for proper discharge piping arrangement F Space heating and domestic water heating with water heater Install Alliance water heater as a separate heating zone Refer to Alliance Installation Operating and Service Instructions for additional information G If boiler is used in connection with refrigeration systems boiler must be installed with chilled medium piped in parallel with the heating boiler using appropriate valves to prevent chilled medium from entering boiler see Figure 10 H If boiler is connected to heating coils lo
75. ulator for that zone to R8888 panel If an Alliance M indirect water heater is used connect the Alliance thermostat and circulator to the Zone 1 terminals of the R8888 Set the thermostat heat anticipator to 0 12 amps NOTICE The Honeywell R8888 Control is available in a three 3 zone Model R8888A and a four 4 zone Model R8888B Up to four 4 R8888 s may be used together to provide control for up to twelve 12 individual zones Only one 1 zone the first zone of the main control will provide priority circulation If more than four 4 zones are required connect additional R8888 s by wiring the A B and C terminals of each control together Each R8888 requires a 120 volt power supply If more than one 1 R8888 is used set the panel type switch to main on the first R8888 and set the panel type switch to expansion on the second third or fourth R8888 8 Conventional Zone Valve Zoned System Refer to Figure 19 Wiring to the most popular models of zone valves is given in Figure 20 Connect the thermostat of each zone and the zone valve for that zone to the R8889 control If an Alliance indirect water heater is used connect the AllianceTM thermostat and zone valve to the zone 1 terminals of the R8889 Set the thermostat heat anticipator to 0 12 amps NOTICE The Honeywell R8889 Control is available in two three 3 zone models and two four 4 zone models Burnham recommends using Model R8889A for
76. without service If damage due to frozen pipes is a possibility the heating system should not be left unattended in cold weather or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative This boiler contains very hot water under high pressure Do not unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure Always wear protective clothing and equipment when installing starting up or servicing this boiler to prevent scald injuries Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler This boiler contains components which become very hot when the boiler is operating Do not touch any components unless they are cool Boiler materials of construction products of combustion and the fuel contain alumina silica heavy metals carbon monoxide nitrogen oxides aldehydes and or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer birth defects and other reproductive harm Always use proper safety clothing respirators and equipment when servicing or working nearby the appliance Failure to follow all instructions in the proper order can cause personal injury or death Read all instruc tions including all those contained in component manufacturers manuals which ar

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